Design of coaxial magnetic gear utilising a novel permanent magnet Halbach array structure

Abstract Mechanical gears are constrained due to wear and tear and call for lubrication. A magnetic gear, utilising permanent magnet (PM) arrays, facilitates the mechanical gear roles. It can withstand high‐speeds and large loads with zero friction. The magnetic gear is more efficacious on account of the least noise, performance, overload protection, and physical isolation between parts than conventional mechanical gears. The quantity of PMs in magnetic structures plays a principal role in its total price, which necessitates optimal arrangements for PMs. Halbach array provides a bigger torque density according to its one‐sided flux. In this research, proposing a novel Halbach array structure, leads to intensification in the one‐sided flux in a much sinusoidally waveform that consequently increases the magnetic torque. These all lead to gain higher torques in constant volumes of magnets. Besides, the magnetic torque ripple and the modulators’ losses are decremented. The new model is based on the variation of the magnetisation angles of the adjacent permanent magnet blocks, in the array. Various states of the magnetisation angles in the array are optimised based on a heuristic method. This is studied in the whole trigonometric range for magnetisation angles characteristics. The prototype is fabricated based on the optimised magnetic gear design and complies with the results.